Composite materials systems for battery housings and covers having improved thermal performance

A composite material housing for a battery pack for reducing or minimizing thermal runaway propagation, the composite material housing comprising:

• a fire-resistant material layer comprising aromatic polyamide fibers continuously or randomly distributed within a first resin matrix;
• a reinforcing material layer disposed near to a surface of the fire-resistant material layer, the reinforcing material layer comprising reinforcing fibers continuously or randomly distributed within a second resin matrix;
• and
• a metallic layer disposed near to a first surface of the reinforcing material layer disposed away from the fire-resistant material layer, wherein in a first operational mode the metallic layer contacts the first surface and in a second operational mode, after exposure to a thermal load of greater than or equal to about 500° C., the metallic layer at least partially delaminates from the first surface and forms one or more insulating air gaps that define a thermal barrier.

A method of forming a composite material housing for a battery for reducing or minimizing thermal runaway propagation, the method comprising:

• disposing a metallic layer into a cavity of a mold;
• disposing a reinforcing material into the cavity near to the metallic layer;
• disposing a fire-resistant material into the cavity near to the reinforcing material;
• disposing a resin or a precursor of the resin into the cavity, the resin or the precursor of the resin surrounding the reinforcing material and the fire-resistant material;
• solidifying the resin or the precursor of the resin to form a composite material comprising a metallic layer, a reinforcing material layer near to the metallic layer, and a fire-resistant material layer near to the reinforcing material layer;
• and
• removing the composite material from the cavity to form the composite material housing.